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Disassembly [08/2020 - ]: Procedure

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  1. REMOVE GENERATOR PULLEY CAP 
    1. Remove the generator pulley cap from the generator pulley with clutch.
      GTY749501Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not reuse the generator pulley cap.
      • If the generator pulley cap is removed, replace the generator pulley cap and generator pulley with clutch with new ones as the correct grease amount cannot be confirmed.

      HINT: 

      Although grease will be observed when the generator pulley cap is removed, this does not indicate a malfunction.

  2. REMOVE GENERATOR PULLEY WITH CLUTCH 
    1. Secure the generator drive end frame in a vise between aluminum plates.
    2. Install SST (A) to SST (B) as shown in the illustration.
      • SST: 09820-63021 
      GTY485885Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Fit the rotor shaft end into SST (A).
      GTY752738Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Rotor Shaft
    4. Fit SST (B) to the generator pulley with clutch.
      GTY770829Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Generator Pulley with Clutch
    5. Loosen the generator pulley with clutch by turning SST (B) as shown in the illustration.
      GTY756822Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Turn
      *b Hold
      NOTE:
      • Check that the generator drive end frame is secured in the vise tightly.
      • Hold SST (A) tightly during the operation.
    6. Remove SST (A) and (B) from the generator pulley with clutch.
    7. Remove the generator pulley with clutch from the rotor shaft.
    8. Remove the generator drive end frame from the vise.
  3. REMOVE GENERATOR REAR END COVER 
    1. Place the generator assembly on the generator pulley with clutch.
      GTY781259Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 3 nuts and generator rear end cover from the generator coil assembly.
      GTY781260Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE GENERATOR TERMINAL INSULATOR 
    1. Remove the generator terminal insulator from the generator coil assembly.
      GTY749516Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY 
    1. Remove the 2 screws and generator brush holder assembly from the generator coil assembly.
      GTY749513Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE GENERATOR COIL ASSEMBLY 
    1. Remove the 4 bolts.
      GTY749514Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, remove the generator coil assembly.
      • SST: 09950-40011 
        1. 09951-04020
        2. 09952-04010
        3. 09953-04020
        4. 09954-04010
        5. 09955-04071
        6. 09957-04010
        7. 09958-04011
      GTY742574Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold
      *b Turn
    3. Remove the washer from the generator rotor assembly.
      GTY443065Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE GENERATOR ROTOR ASSEMBLY 
    1. Remove the generator rotor assembly.
      NOTE:

      Do not drop the generator rotor assembly.

      GTY754257Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Generator Rotor Assembly
      *2 Generator Drive End Frame
  8. INSPECT GENERATOR ROTOR BEARING 

    See step  3

  9. REMOVE GENERATOR ROTOR BEARING 
    1. Remove the 4 screws and retainer plate from the generator drive end frame.
      GTY754910Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a hammer, tap out the generator rotor bearing.
      • SST: 09950-60011 
        1. 09951-00250
      • SST: 09950-70010 
        1. 09951-07100
      GTY757959Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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